Section 01810 COMMISSIONING

Section 01810

COMMISSIONING

PART 1 - GENERAL

1.1 DESCRIPTION

A. This Specification discusses pre-commissioning and commissioning activities. Pre- commissioning activities include all the activities associated with the first time startup of all equipment, instruments, electrical gear and/or process. This includes all checks and tests prior to running equipment and any laboratory tests that may be required to verify proper operation of processes. Full operational tests that demonstrate functionality and reliability will be done during commissioning. It may be necessary to include the installation of temporary facilities to support testing and the removal of temporary facilities when testing is complete. It is the CONTRACTOR’s responsibility to execute proper planning, notification and scheduling. The commissioning activities will involve the ENGINEER, “CONSULTANT” (ENGINEER), CONTRACTOR, OCSD project team, and OCSD staff responsible for the operation, maintenance and facilities oversight.

B. This Specification section identifies the tests and documentation that the CONTRACTOR shall be responsible for in order to complete pre-commissioning and commissioning. All pre- commissioning and commissioning Work, as described in this Specification section, shall be performed by the CONTRACTOR.

1.2 RELATED WORK SPECIFIED UNDER OTHER SECTIONS:

A. The requirements of the following Specification sections and divisions apply to the Work of this Specification section. Other sections and divisions, not referenced below, shall also apply to the extent required for proper performance of this Work.

1. Section 01300, Contractor’s Construction Schedule and Reports

2. Section 01783, Vendor Equipment Manuals

3. Section 01820, Training of OCSD Personnel

4. Refer to other Specification Divisions and Sections for additional requirements relating to testing, including but not limited to the following.

a. Section 17405, Process Instrumentation and Control b. Section 17411, Programming by OCSD

5. Refer to Specification Divisions and/or Sections for additional requirements relating to commissioning, including, but not limited to, the following:

a. Division 11, Mechanical

b. Section 13700, Access Control and Alarm Monitoring System c. Section 13850, Fire Alarm System

d. Division 15, Mechanical

e. Section 16080, Electrical Testing

f. Division 16, Electrical, other applicable sections g. Division 17, Instrumentation and Control

B. In the event of a conflict or contradiction between the specific provisions of the General Requirements and Division 01 “Additional General Requirements”, the respective provisions of the latter shall govern while those other provisions of the General Requirements not in conflict shall remain in full force and effect.

1.3 DEFINITIONS

A. Commencement of Commissioning: Commissioning shall begin with the start of Operational

_{Readiness Test – Part 3.}

B. Gate Report: A report that is accepted by the ENGINEER prior to the CONTRACTOR’s authorization to proceed to the next phase of commissioning.

C. Operational Acceptance: In addition to the General Conditions definition, the successful completion of operator training, Operational Readiness Test – Part 3, Functional Acceptance Test and submittal of current updated redlined As-Builts Drawings shall be requirements of Operational Acceptance. The ENGINEER will issue of Notice of Operational Acceptance to the CONTRACTOR when all requirements are met. Operational Acceptance shall be achieved before proceeding to Commissioning Phase 2.

D. Substantial Completion: The CONTRACTOR may apply for Substantial Completion after the ENGINEER has accepted all Reliability Acceptance Tests and the CONTRACTOR has submitted all Manufacturers’ Certificates of Proper Installation. Also see General Conditions

E. Final Completion: Includes all Work under the Contract see General Conditions

F. System: A system means the overall process, or a portion thereof, that performs a specific function.

1.4 PRE-COMMISSIONING WORK

A. All equipment installed by the CONTRACTOR shall undergo complete pre-commissioning and commissioning. Pre-commissioning is made up of all the activities that shall be completed before the CONTRACTOR is permitted to begin Commissioning. Table 1 lists activities required for pre-commissioning and commissioning. Table 2 provides a listing of systems requiring pre- commissioning to assist with submittals. The table is not comprehensive of all systems to be commissioned.

B. The primary activities for pre-commissioning are construction, factory testing, documentation, component testing, stand-alone equipment testing, and energization of electrical power distribution equipment. This also includes pipe pressure testing, electrical continuity testing, interlock testing, valve leakage testing, and other testing as required in Table 1. The intent is to test isolated equipment and components.

C. Once all components have been tested individually, all electrical power distribution equipment has been functionally tested and energized, and all required deliverables have been approved by OCSD, the CONTRACTOR may request to proceed to Commissioning. If OCSD agrees that the CONTRACTOR has successfully performed all tests and provided all required documentation, the ENGINEER will notify the CONTRACTOR in writing that the CONTRACTOR may begin Commissioning.

Sludge Dewatering and Odor Control at Plant 1 COMMISSIONING Project No. P1-101

February 2012 01810-2

1.5 COMMISSIONING WORK

A. Commissioning is composed of two parts, Phase 1 and Phase 2. Table 1 illustrates some of the tasks.

1. Phase 1 Commissioning will include operator training as well as comprehensive Functional Acceptance Test (FAT). The purpose of the FAT is to test all equipment, instruments and software as an integrated system using clean water from Local, Remote Manual, Remote Automatic, and Remote Cascade modes. In systems that testing cannot be done with clean water, FAT testing will be done with process fluid. The successful completion of the FAT will allow the CONTRACTOR to request that the facility has obtained Operational Acceptance. When all deliverables have been approved and operator and maintenance training is complete, OCSD will notify the CONTRACTOR in writing that the facility has achieved Operational Acceptance and the CONTRACTOR may proceed to the next phase of Commissioning.

2. Phase 2 Commissioning is designed to functionally test the facility as an integrated system under normal operating conditions using wastewater or sludge. The testing includes the Reliability Acceptance Test (RAT) that will be conducted over a period of time that demonstrates the operational reliability of the system. After successful completion of the RAT and all Manufacturers’ Certificates of Proper Operation have been submitted to OCSD, the CONTRACTOR may request that the facility be beneficially occupied.

_{TABLE 1}

PRE-COMMISSIONING (Construction)	COMMISSIONING
	PHASE 1
Equipment Submittal Process Complete	Redline As-Built Drawings received 15 days prior to Operator Training
RFIs and Responses up to Date	Operator Training received 30 days prior to Phase 2
All Factory Demonstration Test (FDT) Reports	Operational Readiness Test - Part 3 (ORT-3)
All Electrical Equipment Tests (Section 16080 and Division 16)	Functional Acceptance Test (FAT)
All Process and Instrumentation Equipment Tests (Division 17)	As-Built Loop Drawings, interconnection drawings, elementary drawings and shop drawings
All Mechanical Equipment Tests (Divisions 11, 13, 14 and 15)	Commissioning – Phase 1 Report
EID Data	Operational Acceptance
SAT Data	Obtain OCSD Approval to Proceed to RAT
Red Lined Loop Drawings, interconnection drawings, elementary drawings and shop drawings
As built P&ID Drawings	PHASE 2
CONTRACTOR Lock-out Tag-out Procedures	Reliability Acceptance Test (RAT)
All Manufacturer Certificates of Proper Installation	All Manufacturer Certificates of Proper Operation
All Pressure Test Reports	Commissioning – Phase 2 Report
All Loop Test Reports	Substantial Completion
All Conductivity and Megger Test Reports	Final Equipment Manuals
All Instrument Calibration Reports	Final Punch List
All configuration reports in print and native Excel format	Final As-Built Drawings
All Electrical Breaker Setting Reports All NETA Test Reports	Final Completion
All Mechanical Alignment Reports
Any and All Operating Permits
Operator & Maintenance Training Plan
Commissioning Plan (accepted prior to 60 percent Progress Payment
All Draft Vendor Equip. Manuals (received 120 days prior to Phase 1)
Factory Demonstration Test - Part 1
Factory Demonstration Test - Part 2
Electrical Power System Energization Test - EPSET
Operational Readiness Test - Part 1 (ORT-1)
Operational Readiness Test - Part 2 (ORT-2)
Pre-commissioning Report
Obtain Authorization by the ENGINEER to Proceed to Commissioning

Sludge Dewatering and Odor Control at Plant 1 COMMISSIONING Project No. P1-101

February 2012 01810-4

_{TABLE 2 – PRE-COMMISSIONING AND COMMISSIONING SYSTEMS}

Fiber & PLCs System

Electrical System

Cake Silos 1 and 2

Cake Silos 3 and 4

Silo Foul Air Collection System

Permanent Truck Load-Out

Interim Truck Load-Out Foul Air Collection System

Interim Truck Load-Out

Trickling Filter Sludge Pumps

Sludge Feed System (PS, WAS, SW, TFS)

Blend Tanks

Bulk Storage Polymer Systems

Thickening - Mix, Age & Feed Polymer Systems

Dewatering - Mix, Age and Feed Polymer Systems

Caustic Soda Bulk Storage & Feed System

Sulfuric Acid Bulk Storage & Feed System

Thickening Centrifuge System

Thickened Sludge Transfer System

Dewatering Centrifuge System

Sludge Cake Conveyance System

Centrate System

Sludge Cake Transfer System

Foul Air Collection Systems

Odor Control System

Bleach Facility

Drainage and Slop Pump Systems

Industrial Water Booster Pumps System

W ater Softener System

Bridge Crane System

Power Building 2 (Engine Generator)

HVAC System

Security System

Fire Alarm System

Sludge Dewatering and Odor Control at Plant 1 COMMISSIONING

1.6 COMMISSIONING TEAM

The Commissioning Team shall be made up of personnel from the CONTRACTOR, OCSD and the “CONSULTANT” (ENGINEER). The CONTRACTOR shall assemble a commissioning team under the direction of a Commissioning Coordinator, duly authorized to commit the CONTRACTOR’s personnel and resources.

CONTRACTOR, Subcontractors and equipment suppliers shall provide technical labor support staff during pre-commissioning and commissioning.

A. Commissioning Coordinator:

The Commissioning Coordinator shall lead all pre-commissioning and commissioning efforts and utilize representatives of the CONTRACTOR’s mechanical, electrical and instrumentation Subcontractors, and others as appropriate for Pre-commissioning and Commissioning activities and testing. This team shall be available at the Work site during normal working hours (8 hours a day, 5 days a week, except Saturdays, Sundays and legal holidays) and shall be available within 2 hours notice at all other times upon notice by telephone. This team shall at all times be equipped and ready to provide for emergency repairs, adjustments and corrections to the equipment and systems installed and modified as a part of this Contract.

1. Qualifications:

The Commissioning Coordinator shall be a California Grade V licensed wastewater treatment plant operator, or California Registered Professional Engineer employed by the CONTRACTOR independent of any of the suppliers, and Subcontractors engaged by the CONTRACTOR. The Commissioning Coordinator name, qualifications, and resume shall be submitted to the ENGINEER for acceptance within sixty (60) days from the Notice to Proceed. The Commissioning Coordinator shall be experienced in all activities related to pre-commissioning and commissioning which includes all facility operations, tests, adjustments and measurements. The Commissioning Coordinator shall have a minimum of five (5) years’ experience in operations and commissioning of facilities of similar type, size, and capacity. The Commissioning Coordinator shall be experienced in all aspects of commissioning and testing or as may be supplemented by similarly experienced assistants.

2. Responsibilities:

a. The Commissioning Coordinator shall direct and be responsible for all pre- commissioning and commissioning tests. The Commissioning Coordinator shall also provide technical instruction for pre-commissioning and commissioning and shall direct the facility operation during equipment testing and facility testing. All facility operation and tests shall be performed in the presence of OCSD personnel unless such presence is expressly waived in writing. The Commissioning Coordinator shall be responsible for the Commissioning Plan and pre-commissioning and commissioning submittals.

b. Other responsibilities include:

c. Prepare the submittals required for the Work of this Specification section d. Develop and implement test procedures

e. Develop and implement the Commissioning Plan

f. Develop a detailed Pre-commissioning and Commissioning Schedule

g. Develop a standard testing log to be used as a record of testing of each equipment item. This log shall:

1) Be acceptable to OCSD

2) Include equipment name, tag and description

3) Have provisions for recording dates of completion for checking, inspection by manufacturer, verification of instrumentation and controls, and completion of tests; and

4) Provide space for problems remaining with equipment and for signature of OCSD

and manufacturer’s representatives indicating acceptance.

h. Develop Commissioning Forms to be used to record testing of each equipment item. Some example forms are included in Attachment A.

i. Furnish labor, materials, consumables, tools, instruments, oils, fluids, test water and services for checking and testing all equipment during pre-commissioning and commissioning. This includes services from manufacturers’ representatives, Subcontractors, electricians, instrumentation technicians, and pipe-fitters that may be required during pre-commissioning and commissioning.

j. Notify OCSD and all respective equipment manufacturers at least twenty one (21) days prior to the date when each equipment system is scheduled to be initially started; also submit testing plan stating schedule and quantity and source of utilities and other materials needed.

k. Be responsible for the preparation and updating of the test schedule and incorporate testing activities in the progress schedule, in accordance with the General Requirements.

l. Obtain and furnish qualified manufacturer’s representative to assist the testing of each equipment type and system in accordance with Manufacturer’s Field Services.

m. Be responsible for all maintenance and servicing of all equipment, electrical gear and instrumentation during pre-commissioning and commissioning.

n. Provide all documentation that equipment is ready for testing.

o. Provide all test reports after each test. The report shall include all data collected during the test.

p. Organize NETA acceptance testing during the Pre-commissioning phase in accordance with Specification section 16080. Tests on newly constructed power systems and apparatus shall be conducted and NETA test reports submitted before energizing, to ensure that the installation and equipment comply with Specifications and intended use as well as with regulatory and safety requirements.

q. Perform the actual pre-commissioning tests and/or supervise the performance of pre- commissioning tests by manufacturer’s field service representatives for various pieces of equipment.

r. Perform the Operational Readiness Tests.

s. Perform the Functional Acceptance Test (FAT). t. Perform the Reliability Acceptance Test (RAT).

u. Operate the facility during RAT with the support of OCSD operators. At the discretion of OCSD, OCSD may choose to intervene and direct operations during RAT in order to protect public health, safety and water quality.

v. Prepare all test reports including the Final Commissioning Report.

w. Formally request training facilities for the classroom portion of the operator and maintenance training thirty (30) days prior to use.

x. Provide operator and maintenance training to the OCSD staff in accordance with

Specification section 01820, Training of OCSD Personnel.

y. Provide Vendor Equipment Manuals in accordance with Specification section 01783, Vendor Equipment Manuals.

z. Conduct monthly commissioning meetings from OCSD’s approval of Commissioning

Coordinator until the start of the Operational Readiness Test Part 1.

aa. Conduct weekly commissioning meetings from the start of the Operational Readiness

Test Part 1 until the completion of the Reliability Acceptance Test. B. OCSD

1. Responsibilities

a. Observe the following tests for compliance with the Contract requirements. OCSD may engage the “CONSULTANT” (ENGINEER) to witness some or all of the tests and participate in the evaluation of the performance. OCSD will not be obligated to provide more than two teams during witnessing of ORT – Parts 2 and 3 and FAT.

1) Factory Demonstration Test – Part 2

2) Operational Readiness Test – Part 2 and 3

3) Functional Acceptance Test

4) Reliability Acceptance Test

b. Furnish and install process control software as specified in Section 17410. OCSD will provide labor and services to supplement the Commissioning Coordinator’s staff during the Functional Acceptance Tests to support the integration of OCSD-furnished process control software with the process instrumentation and control equipment.

c. Provide operator support for the equipment during the Reliability Acceptance Test. d. Provide classroom facilities for operator and maintenance training.

C. CONSULTANT Responsibilities:

1. “CONSULTANT” (ENGINEER) will assist OCSD in review of all test data and results

1.7 MANUFACTURER'S FIELD SERVICES

A. It is the CONTRACTOR’s responsibility to provide the services of the manufacturer’s representatives that apply during equipment installation, facilities testing, pre-commissioning, commissioning and training of OCSD personnel. Where manufacturer’s services are specified, the CONTRACTOR shall furnish a qualified representative of the manufacturer to provide these services.

B. Definitions:

For purposes of furnishing manufacturers’ services, the following definitions shall apply:

1. Manufacturer’s Representatives: Employee of manufacturer who is factory trained and knowledgeable in technical aspects of their products and systems.

2. Person-Day or Instructor-Day: One person for eight (8) hours straight time, exclusive of

Saturdays, Sundays or holidays; does not include travel time. C. Submittals:

CONTRACTOR shall submit the following under this Specification section, as specified in

General Requirements, Shop Drawing Submittals:

1. Qualifications and experience records of proposed manufacturers’ representatives who will assist installation and testing of equipment and conduct training sessions Submittals shall indicate the individual’s factory training including date last trained.

2. After installation, each manufacturer’s representative shall submit to OCSD a written report (Certificate of Proper Installation) certifying that the all equipment specified in Division

11 through Division 17 is installed properly, in accordance with the manufacturer’s installation instructions.

3. During Phase 2 of Commissioning and after the RAT, each manufacturer's representative shall submit to OCSD a written report (Certificate of Proper Operation) certifying that the all equipment specified in Division 11 through Division 17 has been properly installed and lubricated; is in accurate alignment; is free from any undue stress imposed by connecting piping or anchor bolts; and has been operated under full load conditions and that it operated per specifications.

D. Scheduling of Manufacturer’s Field Services:

1. The manufacturer’s representative shall be an experienced, competent, and an authorized representative of the manufacturer of each item of equipment for which field services are indicated in the individual sections of these Specifications. The manufacturer’s representative shall visit the site of the Work to inspect, check, adjust if necessary, and approve the equipment installation. In each case, the manufacturer's representative shall be present when the equipment is being tested and placed in operation. The manufacturer's representative shall revisit the jobsite as often as necessary until all trouble is corrected.

2. The scheduling of all visits to the site by the manufacturer’s field services representative shall be determined by the CONTRACTOR, subject to acceptance by ENGINEER. It is intended that the manufacturers’ representatives’ visits are for the purpose of making equipment inspections and normal adjustments, and not for the purpose of remedying defective Work.

3. Manufacturers’ representatives shall resolve assembly or installation problems attributable to or associated with, their products and equipment.

4. During the testing, the manufacturer’s representative shall assist, as applicable, to perform initial equipment and system adjustments and calibrations.

5. After all acceptance tests have been completed, but prior to Beneficial Occupancy, the CONTRACTOR shall recheck all equipment for proper alignment and adjustment, check oil levels, re-lubricate all bearing and wearing points, and, in general, assure that all equipment is in proper condition for regular continuous operation.

PART 2 - PRODUCTS

2.1 COMMISSIONING PLAN

A. The Commissioning Coordinator shall be responsible for preparing the Commissioning Plan. In developing the Commissioning Plan, the Commissioning Coordinator shall use ATTACHMENT B – Commissioning Flowchart as a guide. The Commissioning Coordinator also shall use Table

2 as a guide for the separate Commissioning Plans that must be prepared.

B. The Commissioning Plan shall be developed to test each equipment as stand alone, multiple equipment tested together to simulate a system, and multiple systems tested together to simulate a plant. All equipment and systems shall be tested for all abnormal operating conditions. This testing shall be in addition to the testing described in individual equipment sections.

C. As a condition precedent to receiving progress payments in excess of 60 percent of the Contract amount, the Commissioning Coordinator shall submit fifteen (15) copies of the commissioning plan and receive ENGINEER’s acceptance for it.

D. Once the ENGINEER has accepted the Commissioning Plan, the Commissioning Coordinator shall reproduce the plans in sufficient number for the Commissioning Coordinator’s purposes and an additional ten (10) copies for delivery to OCSD. No test Work shall begin until the Commissioning Coordinator has delivered the specified number of final commissioning plans to OCSD.

E. Testing:

1. The Commissioning Coordinator shall develop test plans detailing the coordinated, sequential testing of each item of equipment and system installed under this Contract. Each test plan shall be specific to the item of equipment or system to be tested. Test plans shall identify by specific equipment or tag number each device or control station to be manipulated or observed during the test procedure. The specific results to be observed or obtained shall be identified in the plan. Test plans shall also be specific as to support systems required to complete the test Work, temporary systems required during the test Work, Subcontractors' and manufacturers' representatives to be present and expected test duration. As a minimum, the test plans shall include the following features. Test plans shall be revised until they are acceptable to OCSD.

a. FDT / ORT checkout procedures reviewed and approved by the respective equipment manufacturers and OCSD.

b. Detailed testing plans, setting forth step-by-step descriptions of the procedures proposed by the CONTRACTOR for the systematic testing of all equipment and systems installed under this Contract.

c. Procedures shall include statement indicating test objectives, test descriptions, expected test result for each step, forms, and checklists to be used to control and document the required tests.

d. Step-by-step proving procedure for all control and electrical circuits by imposing low voltage currents and using appropriate indicators to affirm that the circuit is properly identified and connected to the proper device.

e. Calibration and configuration of all instruments, drives, actuators, etc., and all equipment requiring programming parameters.

f. Performance testing of each individual item of mechanical, electrical, and instrumentation equipment. Performance tests shall be selected to duplicate the operating conditions described in the Contract Documents.

g. System tests designed to duplicate, as closely as possible, operating conditions described in the Contract Documents.

2. The Commissioning Coordinator shall prepare written test procedures for submittal to the ENGINEER, for acceptance. For each test, the procedure form should clearly define the following:

a. Test Number

b. Purpose of the Test: Describe what is being verified by this particular test.

c. Test Method: Describe the setup for the test and the steps required to complete the test.

d. Criteria: Describe the criteria for passing or failing the test.

_{e. Provide space on the form for the ENGINEER’s comments and for individual sign-off.}

_{f. Test on a Loop-by-Loop Basis: Every loop shall be signed off individually.}

g. Provide a test schedule and time required for the test.

h. Provide a list of all test equipment to be available for the tests.

i. Provide a block diagram showing the test setup arrangement. The diagram shall illustrate the equipment under test, any special test equipment and indicate equipment interconnections.

3. Sample ORT and FAT procedures are included as attachments to this Section. The

CONTRACTOR shall prepare complete ORT and FAT procedures.

4. Test plan and procedures forms shall be revised by the CONTRACTOR until acceptable to the ENGINEER.

5. Staffing for each test identifying roles and responsibilities

a. Organization chart for conducting Pre-commissioning and Commissioning

b. Description of previous experience on similar projects of both personnel and testing companies to be employed in pre-commissioning and commissioning, include list of references complete with phone numbers.

6. Instrumentation list with calibration methods and calibration dates, and configuration with clear indication of new parameters values changed from default setting.

7. Acceptance criteria required to release equipment and systems for commissioning.

8. Statement of successful test.

9. Forms for each test. F. Training:

1. Identify each operator and maintenance training class.

2. Lesson plan for each class.

3. See Section 01820, Training of OCSD Personnel, for more details. G. Schedule:

1. The Commissioning Coordinator shall produce a testing schedule setting forth the sequence contemplated for performing the test Work.

2. The CONTRACTOR’s Baseline Construction Schedule as specified in Division 01 of these Specifications shall include the Commissioning Coordinator’s preliminary test schedule which shall illustrate the anticipated equipment and systems to be tested.

3. The schedule shall show the contemplated start date, duration of the test and completion of each pre-commissioning and commissioning activity.

4. Within thirty (30) days of the ENGINEER’s acceptance of the completed commissioning plan, the CONTRACTOR shall integrate its detailed test schedule, depicting all equipment and systems to be tested, into its Construction Schedule, and submit it as a Construction Schedule Revision for review by the ENGINEER as specified in Division 01 of these Specifications.

5. The test schedule shall be updated weekly, showing actual dates of test Work, indicating systems and equipment testing completed satisfactorily and meeting the requirements of the Contract Documents.

6. Daily Schedule for Testing

a. The Commissioning Coordinator shall begin each day of witnessed testing by meeting with OCSD.

b. The meeting purpose is to review the test schedule, the test results from the previous day, and where applicable, to coordinate the testing schedule with Plant Operations.

c. Note that the Commissioning Coordinator will need to schedule some testing outside normal working hours because of plant operational requirements. The Commissioning Coordinator may be required to rearrange portions of the testing schedule at short notice to accommodate unanticipated plant conditions such as equipment failure or unusually high sewage flows caused by wet weather.

7. Show all tests with beginning and ending dates. At a minimum, the test engineer shall show all NETA testing, FDTs, EPSETs, ORTs, FAT and RAT schedule.

8. Show all operations and maintenance training classes

9. Show all document submittal dates

2.2 PRE-COMMISSIONING AND COMMISSIOINING TESTS

A. The following tests are conducted by the Commissioning Coordinator during Pre- commissioning and Commissioning.

B. Pre-commissioning:

1. The CONTRACTOR shall successfully complete each test and receive written confirmation prior to starting any Commissioning Tests.

2. FDT 1 – Factory Demonstration Test – Part 1: The purpose of this test is for the CONTRACTOR to inspect and witness the testing of the Contract equipment at the manufacture’s facility.

3. FDT 2 – Factory Demonstration Test – Part 2: The purpose of this test is for the OCSD representative(s) to inspect and witness the testing of the Contract equipment at the manufacture’s facility.

4. EPSET – Electrical Power System Energization Test: This test is performed after installation of all electrical switchgear systems and MCCs, after completion of NETA testing of the electrical power distribution system and after receipt of vendor certificate of proper installation. An approved EPSET procedure shall be used to perform this test. The test purpose is for the CONTRACTOR to insure that the electrical power distribution system at the

480 V ac level and above is safe, functional and ready for energization and use during commissioning.

a. This test shall check and document that all local manual, remote and automatic interlocks, switching scenarios, I/O and controls are functional; any temporary power for testing of breakers, switchgear and battery charger system (125 V dc), if required, shall be provided. This test will be witnessed by OCSD personnel. Qualified CONTRACTOR and vendor personnel capable of operating and troubleshooting electrical equipment shall be available during the course of this test. Test shall be directed by the CONTRACTOR’s Commissioning Coordinator.

b. The CONTRACTOR shall submit an EPSET procedure. The EPSET procedure shall include the following:

1) Steps to test and check all modes of operation (local, remote, manual, automatic and PLC), verify all required switching scenarios and functions, and verify that precluded switching scenarios do not occur,

2) Methodology for supplying temporary power (if required),

3) Steps to coordinate administrative control of project electrical equipment that interfaces with existing OCSD electrical equipment to insure that inadvertent energization of existing OCSD equipment does not occur.

c. Prior to commencement of the EPSET, the following documentation shall be submitted and made available to OCSD personnel:

1) An approved EPSET procedure.

2) All associated redlined as-built single line and loop drawings.

3) Electrical vendor equipment manuals and schematics.

4) NETA test reports.

5) CONTRACTOR’s lock-out/ tag-out procedures.

d. Prior to commencement of the EPSET, vendor training of OCSD personnel for electrical equipment shall be competed.

5. ORT 1 – Operational Readiness Test – Part 1: This test is performed after installation and calibration of instruments is complete. The test purpose is for the CONTRACTOR to check and document the complete control system, including I/O to/from PLC register, but excluding the application software, is ready for operation. Also, the equipment shall be tested in local/manual mode for operation and functionality.

_{6. ORT 2: Same as above but witnessed by OCSD personnel.}

C. Commissioning:

1. ORT 3: This is a combined test involving the hardware and the software. This test is a repeat of the ORT 2 except that OCSD will load the previously bench-tested SAT database, the CRISP graphics, and the PLC program into the process workstation.

2. FAT: Functional Acceptance Test – The FAT is a combined effort between OCSD and the CONTRACTOR. The combined software/hardware system is tested from this point forward. The purpose for the test is to insure that the PLC and Operator Graphics software configuration is working in conjunction with the hardware and plant as intended. This test is accomplished with the system on-line under normal operating conditions. Equipment will operate with reclaimed water.

3. RAT – Reliability Acceptance Test: The Purpose for this test is for the CONTRACTOR to demonstrate that all systems are capable of operating continuously in the intended manner for an extended period without failing. During the RAT, the system under test will be operated within design parameters reflecting the day-to-day operation of the facilities for an uninterrupted period as specified in Article 3.2.F.

2.3 PRE-COMMISSIONING AND COMMISSIONING DOCUMENTATION A. Pre-commissioning:

1. The documentation in Table 1 shall be up to date and accepted by the ENGINEER prior to starting any Commissioning activities. The ENGINEER will give written notice to the CONTRACTOR when all the documents are accepted.

B. Commissioning:

1. The following documents shall be submitted by the Commissioning Coordinator to

ENGINEER during commissioning: a. Redline As-Built Drawings. b. Final Equipment Manuals. c. Final Punch List.

d. Final As-Built Drawings.

e. Pre commissioning satisfactory completion report. f. Commissioning – Phase 1 Report.

g. Commissioning – Phase 2 Report.

2.4 DOCUMENTATION

A. The Commissioning Coordinator shall develop a records keeping system to document compliance with the requirements of this Section. Calibration documentation shall include identification (by make, manufacturer, model, serial number, and tag number) of all test equipment, date of original calibration, subsequent calibrations, calibration method, and test laboratory.

B. Equipment and system documentation shall include date of test, equipment number or system name, nature of test, test objectives, test results, test instruments employed for the test, and signature spaces for OCSD’s witness (EPSET, ORT Part 2, ORT Part 3, FAT, RAT) and the CONTRACTOR’s Quality Control Manager (FDT through RAT). A separate file shall be established for each system and item of equipment. These files shall include the following information as a minimum:

1. Metallurgical tests:

2. Factory performance tests

3. Accelerometer recordings made during shipment

4. Field calibration tests¹

5. Field pressure tests¹

6. Field performance tests¹

_{7. Field operational tests}¹

¹ Each of these tests is required even though not specifically listed in the detailed

Specification section.

8. The Commissioning Coordinator shall develop test documentation forms specific to each item of equipment and system installed under this Contract.

9. Once the ENGINEER has reviewed and taken no exception to the forms proposed by the Commissioning Coordinator, the Commissioning Coordinator shall produce sufficient forms, at his expense, to provide documentation of all testing Work to be conducted as a part of this Contract.

10. Reference Documentation

a. The Commissioning Coordinator shall make two sets of the following documentation available to OCSD or its representatives, at the test site:

b. All drawings, specifications, addenda and change-orders;

c. Copy of the approved test procedure for the specific equipment being tested; and d. Copy of drawings and hardware submittals for equipment being tested

2.5 GATE REPORTS

A. The CONTRACTOR shall submit several Gate Reports to the ENGINEER for acceptance in order to continue with the Commissioning process. The reports are described below.

B. Pre-commissioning Report

C. The Pre-commissioning Report is a collection of all test reports, test data, certificates and commissioning forms that are produced during the Pre-commissioning Stage. The first section of this document shall be a summary of the contents certifying that all prescribed tests and procedures have been successfully completed. The Commissioning Coordinator is responsible for producing this document.

D. Commissioning – Phase 1 Report

E. The Phase 1 Report is a collection of all test reports, test data, certificates and commissioning forms that are produced during the Phase 1 Stage. The first section of this document shall be a summary of the contents certifying that all prescribed tests and procedures have been successfully completed. The Commissioning Coordinator is responsible for producing this document.

F. Commissioning – Phase 2 Report:

G. The Phase 2 Report is a collection of all test reports, test data, certificates and commissioning forms that are produced during the Phase 2 Stage. The first section of this document shall be a summary of the contents certifying that all prescribed tests and procedures have been successfully completed. The Commissioning Coordinator is responsible for producing this document.

1. Manufacturer's equipment data:

2. Field recorded dimensional measurements and clearances

3. Pressure, pressure differential, level, flow and other field settings

4. All electrical devices field settings.

5. Operational pressure tests, control system timing tests and settings and other test data specified.

6. Field wiring changes made, including marked up drawings.

2.6 SUBMITTALS

A. CONTRACTOR shall submit the following information in addition to specific equipment where specified in individual sections and paragraphs:

1. Manufacturer’s Certification of Proper Installation of all equipment before Commissioning begins.

2. A complete description of the CONTRACTOR’s plan for documenting the results of all testing, including:

a. Proposed plan for documenting the calibration of all test instruments.

b. Proposed plan for calibration of all instrument systems, including flow meters and all temperature, pressure, weight, and analysis systems.

c. Sample forms for documenting the results of field pressure and performance tests.

3. The credentials and certification of the testing laboratory proposed by the

CONTRACTOR for calibration of all test equipment.

4. Detailed commissioning plan with schedule, prepared by the Commissioning Coordinator, for each equipment item and system. Submit schedule updates showing testing Work not less than 90 days in advance of first scheduled tests. Schedules shall list each piece of equipment or component to be tested, as specified in this Section or by the various sections of the Specifications. Schedules shall include sequence and duration for all testing required including Pre-commissioning Testing and Commissioning Testing.

5. Manufacturer’s Certificates of Proper Operation for each equipment prior to the Notice of

Substantial Completion.

6. Vendor Equipment Manuals as described in Section 01783, Vendor Equipment Manuals. OCSD reserves the right to delay Commissioning if the manuals submitted are incomplete, inaccurate or otherwise unsuitable for use by OCSD. No Contract extension or extra cost shall be allowed for the delays in Commissioning due to Vendor Equipment Manual submittal delay.

7. Lock-out and Tag-out Procedures and Policies that will be used by the CONTRACTOR

during pre-commissioning and commissioning

B. Submit design and details of temporary test facility (if required)

C. Submit test reports in conformance with requirements specified herein

1. Preliminary copies of test data in field report form shall be made available to the ENGINEER with in two days after completion of each test. This information shall remain available to the ENGINEER for the duration of the Project.

2. Submit five (5) bound copies of field test reports of checkout and testing of all equipment within thirty (30) days after completion of testing

D. Formal Reports

1. Submit ten (10) bound copies of Gate Reports within thirty days after completion of last test.

PART 3 - EXECUTION

3.1 PRE-COMMISSIONING AND COMMISSIONING ACTIVITIES

A. The following is a partial list of activities that shall be complete during each stage of

Commissioning.

B. Pre-commissioning:

1. Electrical Service Tie-ins.

2. Electrical Testing (Section 16080 and Division 16).

3. Electrical Equipment is Clean and Energized.

4. Mechanical Equipment is Clean and Energized.

5. Verify Rotation of Motors.

6. Perform Local Manual Mode Tests.

7. Piping Equipment is Complete and Pressure Tested.

8. Pipe Supports Complete.

9. Pipe is Clean of Debris (inside and out).

10. Verify Valve Operation and Positions for Commissioning.

11. I&C System is Complete and Energized.

12. Perform Wiring and Loop Tests.

13. PCI Programming Complete.

14. Perform Factory Demonstration Tests (FDT).

15. Perform Electrical Power System Energization Test (EPSET).

16. Perform Operational Readiness Test – Part 1 and Part 2 (ORT 1 and 2).

17. Pre-commissioning Requirements - Specification section 17405. C. Commissioning:

1. Perform Operational Readiness Test – Part 3 (ORT 3).

2. Operator Training.

3. Prepare As-Built Drawings.

4. Facilities Acceptance Test (FAT).

5. Reliability Acceptance Test (RAT).

6. Prepare Final Equipment Manuals.

7. Complete Final Punch List.

3.2 GENERAL EQUIPMENT AND SYSTEM TESTING

A. This Specification section covers general equipment, instrumentation and system testing during pre-commissioning and commissioning.

B. Testing Coordination:

1. Coordination of Testing with Plant Operation: CONTRACTOR shall notify OCSD not less than 72 hours in advance of the planned start of equipment testing in order to coordinate project testing with plant operation.

C. Materials and Equipment:

1. The CONTRACTOR shall provide all testing and recording devices required for specified tests. The Commissioning Coordinator shall determine or approve the type, number and quality of all such devices. Obtain ENGINEER's acceptance of such equipment including oscillograph and test equipment calibration certification.

2. The CONTRACTOR shall provide all lubricating oil, hydraulic oil, grease, packing, and insulating and lubricating fluids and filters required to clean, blow out, flush, and initially charge equipment and systems.

D. Pre-commissioning Tests and Checks:

1. Cleaning and Checking: Prior to testing of all equipment:

a. Inspect and clean equipment, devices, and connected piping so they are free of foreign material.

b. Lubricate equipment in accordance with manufacturer’s instructions.

c. Turn rotating equipment by hand and check motor-driven equipment for correct rotation.

d. Open and close valves by hand and operate other devices to check for binding, interference, or improper functioning.

e. Check power supply to electric-powered equipment for correct voltage. f. Check for proper equipment alignment.

g. Obtain manufacturer’s certification of proper installation.

2. Ready-To-Test Determination: All equipment shall be determined ready to test by the

ENGINEER based on the following:

a. Notification in writing by the Commissioning Coordinator of equipment and system readiness for testing.

b. Submittal and acceptance of detailed Commissioning Plan.

c. Receipt of acceptable vendor equipment manuals as specified in Specification section 01783, Vendor Equipment Manuals.

d. Cleanliness of equipment, devices, and connected Work.

e. Adequate completion of Work adjacent to, or interfacing with, equipment to be tested. f. Availability and acceptability of manufacturer’s representative to assist testing of

^{respective equipment, and satisfactory fulfillment of other specified manufacturers’}

responsibilities.

3. Perform Pre-commissioning Tests and make adjustments as needed. Pre- commissioning Tests shall include, but not be limited to, the following:

a. Check for correct connections, operation, and performance of electrical power distribution equipment such as switchgear, motor control centers, uninterruptible power system, and dc system specified in Specification section 16080, Electrical Testing, and elsewhere in Division 16.

b. Check for correct operation and perform calibration tests of position, pressure, level, flow, speed, temperature and all other monitoring instruments.

c. Perform Pre-commissioning Testing and conduct operating tests for all mechanical equipment, systems and accessories specified in Divisions 11, 13, 14 and 15 technical Specification sections. Inspect, adjust and operate the equipment and systems:

1) Test gates and valves under dry conditions using manual controls. Repeat operation and adjust as necessary until proper timing is obtained. Place gates and valves in their normal position.

2) Operate pump & motor systems (e.g., motor cooling, seal water, lubrication, etc.)

to verify proper operation.

3) Operate all mechanical systems to verify proper operation:

a) Plumbing and drainage systems b) Ventilation systems

c) Plant water, industrial water, City water and plant air systems.

4) Check and operate pipeline accessories such as air valves and blowoffs

5) Verify electrical operation of auxiliaries including:

a) Solenoids

b) Limit switches

c) Remote indicating devices

d) Position, pressure and level transmitters

d. Inspect and verify proper anchorage and grounding of equipment.

e. Perform leak tests of pipe, fittings, gaskets and seals.

f. Perform tests of on-off controls, limit switches and indicating lamps.

g. Perform tests of alarms, signals, and fail-safe or system shutdown controls.

h. Perform all pre-commissioning tests specified in other sections of these

Specifications.

i. Perform tests recommended by the manufacturer’s field service representatives and/or as required by manufacturer's catalogs or specifications.

j. Additional tests required by manufacturer's modifications to meet specified requirements, or tests required due to failures of CONTRACTOR-furnished equipment, shall be at the CONTRACTOR’s expense with no additional cost to OCSD.

4. A label shall be attached to all devices to indicate that testing has been performed, indicating the date that tests were completed and initialed by the person conducting the tests.

5. ORT – Part 1 and Part 2 shall be directed by the Commissioning Coordinator.

6. Provide Pre-commissioning Test Report.

7. Obtain authorization by the ENGINEER to proceed with Commissioning. E. Commissioning Phase 1 Tests:

1. Phase 1 tests shall be directed by the Commissioning Coordinator to determine that all features and equipment systems and subsystems have been properly designed, manufactured, installed and adjusted, function properly as specified and are capable of operating simultaneously and continuously in the “local” and “auto” control modes at all capacities throughout their operating range. For wastewater systems, clean water will be used for all tests.

a. Phase 1 tests shall include, but are not necessarily limited to, the following equipment or systems:

_{Equipment or System For Phase 1 Tests, refer to:}

Thickening Centrifuges, Dewatering Centrifuges, Non-clog Centrifugal Pumps, Submersible Sump Pumps, Progressive Cavity Pumps, Cake Pumps, Diaphragm Metering Pumps, Silo Dischargers, Grinders, Screw Conveyors, Mixers, Truck Loadout Discharger and Centrifugal Booster Pumps

Division 11 Sections

_{Laboratory Equipment Section 11950}

HDPE Tanks, FRP Tanks, and Truck

_Scale

Division 13 Sections

_{Access Control and Alarm Monitoring System Section 13700}

Fire Alarm System

Hydraulic Elevator and Hoisting Equipment

Section 13850

Plug Valves, Butterfly Valves, Check Valves, Ball Valves, Diaphragm Valves, Gate Valves, Miscellaneous Valves and Valve Operators

Polymer High Energy Make Down Units

Hot Water Heater and Circulation pump, Automatic Water Softener and Neutralization Tank

HVAC Equipment

Air Cooled Reciprocating Chiller

Fiberglass Ducting, Inline Fans and Dampers

Odor Control System including exhaust fans, Multi-Stage Scrubbers and Carbon Adsorbers

Division 14 Sections

Sections 15100 through 15115

Section 15122

Section 15400

Section 15605

Section 15662

Section 15810

_{Section 15885}

Electrical Section 16080 & Div. 16 Sections

Process Instrumentation and Control; Section 17405 & Div. 17 Sections

2. Operational Readiness Test – Part 3:

a. Operational Readiness Tests shall be directed by the Commissioning Coordinator and performed herein.

b. This is a combined test involving the hardware and the software. This test is a repeat of ORT – Part 2 except that OCSD will load the previously bench-tested SAT database, the CRISP graphics, and the PLC program into the process workstation. A PCI representative and the CONTRACTOR shall perform a network-by-network review of program interaction. Any and all assistance to troubleshoot, correct and/or modify and test the software program shall be provided by the CONTRACTOR. If the software programming is done by OCSD, the assistance shall be limited to all other (field and panel wiring) items except OCSD-programmed software. As a minimum, CONTRACTOR shall include the following number of working days in the project schedule to test the PLC systems:

1) Thickening Centrifuge PLCs 5 working days for each PLC

2) Thickening PLC: work days 10 working days

3) Dewatering Centrifuge PLCs 5 working days for each PLC

4) Dewatering PLC: work days 10 working days

5) Scrubber PLC: work days 5 working days

6) Utility PLC: work days 5 working days

7) Polymer PLC 10 working days

8) Truck Loading PLC 10 working days

9) Power Monitoring (Thickening & Dewatering) PLC 4 working days

10) Power Monitoring (Power Building 2) PLC 4 working days

11) Bleach System PLC 4 working days

12) Gateway PLC Between Dewatering Centrifuge and HMI (if required): 5 working days

c. Note: items (1), (3) and (12) shall be the Centrifuge supplier’s responsibility.

d. This test is performed by the CONTRACTOR after installation and calibration of instruments is complete. The test purpose is for the CONTRACTOR to pre-check and document that the complete control system, including the I/O to/from PLC register including the application software, are ready for operation. The CONTRACTOR shall:

1) Check the complete control system for proper installation and adjustment on a loop by loop and component by component basis.

2) Test and calibrate all equipment connected to the control system, whether supplied by the CONTRACTOR or not. Equipment connected to the control system but not supplied by the CONTRACTOR includes existing primary elements, transmitters, cabling, junction boxes, pumps, automatic valves, etc.

e. Notify the ENGINEER in writing if equipment tested but not supplied by the

CONTRACTOR is faulty.

f. Make ORT tests with power applied to the equipment. Check loops from the primary element in the field through all cabling and junction boxes to the PLC database register. Configure the PLC software to support testing.

g. Co-ordinate with OCSD staff before testing major equipment not supplied by the

CONTRACTOR. (For example, variable frequency drives).

h. Exercise equipment in a manual mode, which is independent of the computer system.

1) Stroke all valves and gates between end of travel limits. Verify stop positions.

2) Bump all motor-driven devices.

3) Prove all hardwired interlocks with equipment energized.

i. Use loop status reports to organize and track inspection, adjustment and calibration of each loop. The report shall include the following:

1) Project name and loop number

2) Tag number for each component

3) Check off/sign offs for each component

4) Tag/identification in place in accordance with OCSD requirements.

5) (5) Installation complete in accordance with OCSD requirements

6) (6) Termination wiring/tubing

7) (7) Calibration/adjustment

8) (8) The checked out loop drawings, and/or redlined loop drawings. j. Check-offs and sign-offs for the loop:

1) Panel interface terminations

2) Input/Output interface terminations with the PLC

3) Input/Output checked to PLC database

4) Total loop operational

5) Correct loop drawing and/or redlined loop drawing.

k. Note all deviations from specified final operating configuration.

l. For Component Calibration Sheets refer to the Article 3.7 below.

m. Maintain Loop Status Reports and Calibration Sheets at the project site and make them available to the ENGINEER at all times. Submit up-to-date copies at the end of each week, for the tests completed that week.

n. CONTRACTOR shall note that OCSD PCI staff generally work four days per calendar week. The two PLC tests shall not overlap in the schedule except with written permission of the ENGINEER.

3. Functional Acceptance Tests shall be directed by the Commissioning Coordinator and performed as specified herein.

a. The FAT is a combined effort between OCSD and the CONTRACTOR. The combined software/hardware system is tested from this point forward. The purpose of the test is to ensure that the PLC and Operator Graphics software configuration is working in conjunction with the hardware and plant as intended. This test is accomplished with the system on-line under normal operating conditions. Equipment will operate with clean water when possible. Application software problems encountered during the test shall be investigated and corrected by the CONTRACTOR. Problems with PLC and/or SCADA software programming done by OCSD will be corrected by OCSD. The CONTRACTOR shall provide a qualified person familiar with the installation and of PLC panels, full time for the duration of the test. Prior to the test, the CONTRACTOR shall submit a written FAT procedure to OCSD for acceptance. OCSD acceptance of the procedure prior to the start of the FAT is required. CONTRACTOR shall include in the schedule at least half the time as allocated to ORT3 for to troubleshoot each PLC system. The two PLC tests shall not overlap in the schedule, except with written permission of OCSD PCI division.

b. Pump and Motor Testing Using Temporary Test (Piping) Loop:

1) Phase 1 tests of pumps, motors and VFD’s shall be performed to verify pump performance and operation over the full operating range from minimum head / low flow up to maximum head / maximum capacity. This testing may require temporary piping. CONTRACTOR shall size, design, furnish, install, remove when done and store onsite at a location designated by OCSD, the temporary test piping to facilitate field testing of the pumps and motors as specified in Section 11210.

a) CONTRACTOR shall submit drawings and all details of the test loop facility in accordance with General Requirements, Section 28, Shop Drawing Submittals.

(1) The test piping should include the following key components:

(2) The piping connection shall include a flow metering device. The flow metering device may be an orifice plate, insertion magmeter, or other device proposed by CONTRACTOR and accepted by OCSD. The full range accuracy of the flow metering device shall be plus or minus one (1) percent.

(3) The piping shall include a throttling valve that creates a backpressure on the pumps to replicate the full and reduced speed head operating range of the pumps.

(4) The piping connection shall include necessary pipeline appurtenances such as air release and vacuum relief valves, drains, and instrumentation connections. All appurtenances shall be coated in accordance with Section

09800.

F. Commissioning Tests Phase 2:

1. Phase 2 of the entire project, or a specified portion thereof, shall be overseen by the

Commissioning Coordinator after the Phase 1 Tests are completed and accepted by OCSD.

2. Equipment shall be operated only by the Commissioning Coordinator’s personnel. OCSD personnel may operate equipment but only under the direction of the Commissioning Coordinator and with the consent of OCSD. Subject to OCSD acceptance, the Reliability Acceptance Test shall begin as soon as possible after completion of the Functional Acceptance Test. This test shall be directed by the Commissioning Coordinator. The Reliability Acceptance Test will be considered complete, in the opinion of OCSD, when the entire project or specified portion thereof has operated properly without significant interruption for the continuous period specified in Article 3.2.F.4.

3. Significant interruption:

a. “Significant interruption” during the Reliability Acceptance Test may include any of the following events:

1) Failure of a system (process, control, etc.) that is not permanently corrected within six (6) hours after such failure occurs.

2) Failure of a process equipment unit (mechanical, electrical, instruments, etc.) that is not permanently corrected within eight (8) hours after such failure occurs.

b. “Permanently corrected” means without a repeat failure during the remaining duration of Phase 2 and shall consist of all of the following:

1) Work repaired and replaced to conform with specified requirements

2) Parts and components replaced as recommended by original manufacturer without impacting on warranty, and conforming with reviewed submittals

3) Piping and valves properly installed and connected

4) Wiring properly terminated

5) Accessories, including spare parts and lubricants, furnished as specified

6) The facility is back on line and operating within normal operating parameters.

c. Occurrence of a significant interruption shall require Phase 2 then in-progress to be stopped and restarted at time equals zero (begin at Day 1 again) after permanent corrections are made.

4. Reliability Acceptance Test (RAT):

a. The RAT shall be performed in phases for the various facilities in accordance with the Work area requirements, system to be started and the phase of construction. The following are the areas to be started:

1) Dewatered Sludge Cake Storage Silos, following modifications

2) Temporary Loadout Facility

3) Existing Loadout Facility, following modifications

4) Trickling Filter Sludge Pumps, following modifications

5) Bleach Facility, following modifications

6) Odor Control Facility

7) Blend tanks, polymer feed, thickening centrifuges, thickened sludge transfer and centrate

8) Digested sludge feed, dewatering centrifuges, cake conveyance and cake transfer

b. The time and sequence of each of the RATs shall be based on the construction sequence and work restrictions discussed in Specification section 1140, Work Restrictions.

c. The RATs shall be coordinated with OCSD Plant No. 1 Operations. Routine daily meetings shall be indicated in the plan. The meetings shall be conducted to communicate daily activity being conducted during the RAT.

d. The RATs shall be initiated after completion and acceptance of the associated FATs by the DISTRICT. During each RAT, the tested system shall be operated with the associated fluid or gas (e.g., raw sludge, digested sludge, sludge cake, foul air, bleach) at or near design flow conditions. The RAT plan shall be written by the CONTRACTOR indicating the intended average daily flow. After the test is completed, the process will remain in normal operating condition.

e. The selected operating flow for the RAT will influence the feed flow requirements for each train. The plan shall indicate the steps that will be taken to facilitate these quantities. The plan shall discuss the steps needed to provide gradual flow increases to the tested train. The plan shall indicate procedures for changes in train operating conditions for testing of different modes.

f. After the RAT, the treatment train flow will remain at the test flow condition. The train will be operated by OCSD Plant No. 1 Operations.

g. The RAT plan shall indicate the time needed to place all trains into service.

h. The RAT Plan shall show the process control tests needed to monitor each specific process train to be tested. The required process control tests, required monitoring, and report shall be, at a minimum, those tests and monitoring used by OCSD Plant No. 1

Operations. At the end of the RAT, the report shall be submitted in hard copy and electronic formats. The electronic format shall be submitted to allow it to be uploaded into existing OCSD software; the program needed to achieve this compatibility must be discussed in the plan.

i. Each of the eight areas listed above shall have separate RATs, which differ with respect to process components involved and system operational criteria. Therefore, the CONTRACTOR shall provide a detailed RAT for each area in his commissioning plan as discussed in the following sections:

1) Dewatered Sludge Cake Storage Silos, following Modifications a) First RAT – Following Closure of Openings between Silos

(1) The RAT shall be performed on each pair of silos after sealing the opening between them to assess the operation of the silos with existing equipment, instrumentation and the modified foul air collection system. The sequence shall be as follows:

(a) Silos 1 & 2

i. Existing cake pumps, valves, level indicator/transmitter, loading bin and other instrumentation.

ii. Operate for 8 hours

(b) Silos 3 & 4

i. Existing cake pumps, valves, level indicator/transmitter, loading bin and other instrumentation.

ii. Operate for 8 hours

b) Second RAT – Following Modifications to Live Bottom and Cake Pumps

(1) The RAT shall be performed on each pair of silos after upgrading the silos with the equipment to assess the operation of the silos with new equipment, instrumentation and the modified piping. Two RATS are required for Silos 1 & 3 to address interim and final equipment arrangements. The sequence shall be as follows:

(a) Silos 1 & 3 – Interim Equipment Arrangement:

i. New cake pumps, sliding frames, hydraulic packs, valves, level indicator/transmitter, new piping, existing loading bin and other instrumentation and control. Hydraulic packs located on basement floor.

ii. Operate for 7 days

(b) Silos 2 & 4

i. New cake pumps, sliding frames, hydraulic packs, valves, level indicator/transmitter, new piping, existing loading bin and other instrumentation and control.

ii. Operate for 7 days

(c) Silos 1 & 3 – Final Equipment Arrangement

i. New cake pumps, sliding frames, hydraulic packs, valves, level indicator/transmitter, new piping, existing loading bin and other instrumentation and control. Hydraulic packs relocated to mezzanine platform

ii. Operate for 2 days

c) Third RAT – Following Commissioning of Dewatering Centrifuges

(1) The RAT shall be performed on all silos after commissioning of the dewatering centrifuges to test silo cake convenience system when transporting drier sludge cake.

(a) New cake pumps, sliding frames, hydraulic packs, valves, level indicator/transmitter, new piping, existing loading bin and other instrumentation and control.

(b) Operate for 4 days

2) Temporary Loadout Facility

a) The RAT shall be performed on the Temporary Loadout Facility after completion of the new enclosure for to assess the operation of the scale with existing equipment, instrumentation and the modified foul air collection system. The sequence shall be as follows:

(1) New cake pumps (new pumps under the upgraded silos), valves, truck scale, foul air collection, level indicator/transmitter, loading bin and other instrumentation.

(2) Operate for 7 days

3) Existing Loadout Facility, following Modifications

a) First RAT – Using Belt Press Dewatered Cake

b) The RAT shall be performed on the existing loadout building after completion of the loadout system upgrade to assess the operation of the new and existing equipment, instrumentation and the modified foul air collection system. The cake silos shall contain belt press dewatered cake. The sequence shall be as follows:

(1) New cake pumps (new pumps under the upgraded silos), silos, cake piping, valves, truck scale, foul air collection, level indicator/transmitter, loading bin and other instrumentation and control.

(2) Operate for 7 days

c) Second RAT – Using Centrifuge Dewatered Cake

d) The RAT shall be performed on the existing loadout building after completion of the loadout system upgrade to assess the operation of the new and existing equipment when fed drier dewatered cake. The cake silos shall contain centrifuge dewatered cake. The sequence shall be as follows:

(1) New cake pumps (new pumps under the upgraded silos), silos, cake piping, valves, truck scale, foul air collection, level indicator/transmitter, loading bin and other instrumentation and control.

(2) Operate for 4 days

4) Trickling Filter Sludge Pumps, following Modifications

a) The RAT shall be performed after the installation each of two Trickling Filter

Sludge Pumps. The sequence shall be as follows: (1) Pump 12 BPMP100

(a) Existing discharge destination, New pump, flow meter, piping and other instrumentation and control.

(b) Operate for 7 days

(2) Repeat for Pump 12 BPMP110

(a) Existing discharge destination, New pump, flow meter, piping and other instrumentation and control.

(b) Operate for 7 days

5) Bleach Facility, following Modifications

a) First RAT – Following Installation of New Storage Tank and Pump Relocation

(1) The RAT shall be performed after completion of the new storage tank installation and relocation of each of the existing four pumps in bleach station

2. The sequence shall be as follows:

(a) Pump 17 GPMP130

i. Existing discharge destination, level indicator/transmitter, flow meters, Bleach piping and other instrumentation and control.

ii. Operate for 8 hours

(b) Repeat for Pump 17 GPMP135

i. Existing discharge destination, level indicator/transmitter, flow meters, Bleach piping and other instrumentation and control.

ii. Operate for 8 hours

(c) Repeat for Pump 17 GPMP140

i. Existing discharge destination, level indicator/transmitter, flow meters, Bleach piping and other instrumentation and control.

ii. Operate for 8 hours

(d) Repeat for Pump 17 GPMP255

i. Existing discharge destination, level indicator/transmitter, flow meters, Bleach piping and other instrumentation and control.

ii. Operate for 8 hours

b) Second RAT – Following Installation of Odor Control Bleach Pumps

(1) The RAT shall be performed on the existing Bleach station after completion of the Bleach feed pump system to the odor control system, the odor control system and the foul air collection system in it is final form. The sequence shall be as follows:

(a) Solids scrubbers 1 & 2

(b) Bleach feed pumps, Dampers, foul air collection system inline fans, Caustic Soda storage tank and feed pumps, sulfuric acid storage tank and feed pumps, solids scrubbers, carbon adsorbers, exhaust fans, Ph probes, ORP probes, air flow meters pressure drop indicator/transmitter and other instrumentation and control.

(c) Operate for 7 days

i. Repeat for solid scrubbers 2 & 3 (d) Operate for 7 days

6) Odor Control Facility:

a) The RAT shall be performed on the Odor Control Facilities after completion of the existing loadout system upgrade, removal of the foul air collection system associated with the temporary loadout facility, RAT of the Bleach station initial phase, and after air balance of the foul air collection system in all areas simultaneously. The sequence shall be as follows:

(1) Solids Scrubbers 1 & 2:

(a) Blending tanks, thickening centrifuges, thickened sludge wet wells, dewatering centrifuges, classifiers, cross conveyors, collector conveyors, cake pumps, silo cake pumps, silos, loadout bin, loadout bay, centrate wet wells, sump pump stations, centrate piping, dampers, foul air collection system inline fans, Caustic Soda storage tank and feed pumps, sulfuric acid storage tank and feed pumps, solids scrubbers, carbon adsorbers, exhaust fans, Ph probes, ORP probes, air flow meters pressure drop indicator/transmitter and other instrumentation and control.

(b) Operate for 7 days.

(2) Repeat for Solid Scrubbers 2 & 3 with Carbon Adsorbers 1 & 2 (a) Operate for 7 days.

7) Blend Tanks, Polymer Feed, Thickening Centrifuges, Thickened Sludge Transfer and Centrate

a) The First Phase of the RAT shall be performed on a train by train basis with one train running blended sludge and the other running primary sludge only. Each train will include one blending tank and a thickening centrifuge train. The sequence shall be as follows:

(1) Blend tank 1 and thickening centrifuge train 1 on blended sludge and blend tank 2 and thickening centrifuge train 2 on primary sludge.

(a) Blending tanks, grinders, sludge feed pumps, polymer mix and feed system, thickening centrifuges, thickened sludge wet wells, centrate wet wells, stations, centrate piping, dampers, foul air collection system inline fans, thickened sludge pumps, digesters, centrate pumps, Caustic Soda storage tank and feed pumps, sulfuric acid storage tank and feed pumps, solids scrubbers, carbon adsorbers, exhaust fans, flow meters, pressure indicator/transmitter and other instrumentation and control.

(b) Operate for 4 days.

(2) Repeat for blend tank 2 and thickening centrifuge train 2 on blended sludge and blend tank 3 and thickening centrifuge train 3 on primary sludge.

(a) Operate for 4 days.

(3) Repeat for blend tank 3 and thickening centrifuge train 3 on blended sludge and blend tank 1 and thickening centrifuge train 1 on primary sludge.

(a) Operate for 4 days.

b) The Second Phase of the RAT shall be performed using combinations of blend tanks, centrifuge trains and feed sludge types as directed by OCSD.

(1) Operate for 33 days.

8) Digested Sludge Feed, Dewatering Centrifuges, Cake Conveyance and Cake

Transfer

a) The First Phase of the RAT shall be performed on a train by train basis with two centrifuge trains running on one collector conveyor and one cake transfer pump. The sequence shall be as follows:

(1) Collector conveyor 1 and dewatering centrifuge train 1 and dewatering centrifuge train 2.

(a) Holding tanks, digested sludge grinders, sludge feed pumps, polymer mix and feed system, dewatering centrifuges, classifiers, cross conveyors, collector conveyors, cake pumps, silo cake pumps, silos, loadout bin, loadout bay, centrate wet wells, centrate piping, centrate pumps, dampers, foul air collection system inline fans, Caustic Soda storage tank and feed pumps, sulfuric acid storage tank and feed pumps, solids scrubbers, carbon adsorbers, exhaust fans, flow meters, pressure indicator/transmitters and other instrumentation and control.

(b) Operate for 4 days.

(2) Collector conveyor 2 and dewatering centrifuge train 3 and dewatering centrifuge train 2.

(a) Operate for 4 days.

b) The Second Phase of the RAT shall be performed using combinations of centrifuge trains and collector conveyors as directed by OCSD.

(1) Operate for 37 days.

5. Retesting of Equipment:

a. When testing or operation of the equipment demonstrates that the equipment does not meet the specified requirements, CONTRACTOR shall repeat or perform all additional tests as necessary and required by OCSD.

b. When the re-testing is caused by failure of CONTRACTOR to perform the Work satisfactorily, as a required procedure, or for minor changes to the equipment, CONTRACTOR shall not be granted an increase in the Contract Price, nor an extension of Contract Time.

6. Continuous Operation:

a. After successful Reliability Acceptance Test of a particular equipment type or system, OCSD may elect to operate a portion of the equipment or system for continuous operation. Such operation shall not interfere with testing of other equipment and systems that may still be underway, and shall not preclude the need to start up the portion operated in combination with the rest of the facility when all testing is completed.